U.S. patent number 10,081,771 [Application Number 15/140,409] was granted by the patent office on 2018-09-25 for rapid compression apparatus for treatment of moisture-containing bio-material.
This patent grant is currently assigned to ENGINUITY WORLDWIDE, LLC.. The grantee listed for this patent is Enginuity Worldwide, LLC. Invention is credited to Robert L. Heimann.
United States Patent |
10,081,771 |
Heimann |
September 25, 2018 |
Rapid compression apparatus for treatment of moisture-containing
bio-material
Abstract
An apparatus, a system, and a method for heat treating a
moisture-containing or water-laden material are provided. The heat
treatment can be drying for dehydration, gasification, or full
carbonization. The system comprises a feeding mechanism, and a
rapid compression unit (RCU) apparatus having a screw, a barrel,
and one or more flow disrupters. The system can further include a
reflux condenser, an aftercooler stage, a second condenser for
particle filtering, and an exit mechanism. The one or more flow
disrupters are located on an inner surface of the barrel and
project into the passageway created by the screw and the barrel.
The screw is sized to fit within the barrel such that flow
disrupter does not contact the screw. The one or more flow
disrupters cause the water-laden material to fold over onto its
self, thereby, allowing for the occurrence of more uniform
drying.
Inventors: |
Heimann; Robert L. (Centralia,
MO) |
Applicant: |
Name |
City |
State |
Country |
Type |
Enginuity Worldwide, LLC |
Mexico |
MO |
US |
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Assignee: |
ENGINUITY WORLDWIDE, LLC.
(Mexico, MO)
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Family
ID: |
56008857 |
Appl.
No.: |
15/140,409 |
Filed: |
April 27, 2016 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20160312123 A1 |
Oct 27, 2016 |
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Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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62153130 |
Apr 27, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C10B
27/06 (20130101); C10J 3/62 (20130101); F26B
11/12 (20130101); F26B 23/00 (20130101); F26B
25/003 (20130101); C10J 3/723 (20130101); C10B
53/02 (20130101); C10J 3/30 (20130101); F23G
5/033 (20130101); F26B 25/04 (20130101); F23G
5/027 (20130101); C10J 3/007 (20130101); C10B
47/12 (20130101); F23G 2203/8013 (20130101); F23G
7/10 (20130101); C10J 2200/158 (20130101); C10J
2300/0916 (20130101); F23G 2201/30 (20130101); F26B
2200/10 (20130101); F26B 2200/24 (20130101); F26B
2200/06 (20130101); F23G 2205/121 (20130101); C10J
2300/0909 (20130101); F23G 2201/20 (20130101); Y02E
50/10 (20130101); F26B 2200/02 (20130101) |
Current International
Class: |
C10J
3/00 (20060101); F26B 25/00 (20060101); F26B
23/00 (20060101); F26B 11/12 (20060101); C10B
47/12 (20060101); F26B 25/04 (20060101); C10J
3/72 (20060101); C10J 3/62 (20060101); C10J
3/30 (20060101); C10B 53/02 (20060101); C10B
27/06 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2009102131 |
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Aug 2009 |
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WO |
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2011100695 |
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Aug 2011 |
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WO |
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2014027809 |
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Feb 2014 |
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WO |
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Other References
ISRWO of PCT/US2016/029620 dated Jul. 5, 2016. cited by applicant
.
Bridgwater, A.V.; Peacocke, G.V.C. 2000. Fast pyrolysis processes
for biomass. Renewable and Sustainable Energy Reviews. vol. 4: pp.
1-73. cited by applicant .
Demirbas, Ayhan. 2007. The influence of temperature on the yields
of compounds existing in bio-oils obtained from biomass samples via
pyrolysis. Fuel Processing Technology. vol. 88(6): pp. 591-597.
cited by applicant .
Yasuhara, Akio; Sugiura, Ginji. 1987. Volatile Compounds in
Pyroligneous Liquids from Karamatsu and Chishima-sasa. Agricultural
and Biological Chemistry. vol. 51(11): pp. 3049-3060. cited by
applicant .
Azargohar, R.; Dalai, A.K. 2006. Biochar as a precursor of
activated carbon. Appl. Biochem. Biotechnol. vol. 129-132: 762-773.
cited by applicant .
Dalai, Ajay K; Azargohar, R. 2007. Production of Activated Carbon
from Biochar Using Chemical and Physical Activation: Mechanism and
Modeling. Materials, Chemicals, and Energy from Forest Biomass.
Chapter 29: pp. 463-476. cited by applicant .
Azargohar, R.; Dalai, A.K. 2008. Steam and KOH activation of
biochar: Experimental and modeling studies. Microporous and
Mesoporous Materials. vol. 110 (2-3): pp. 413-421. cited by
applicant .
Sadaka, Samy; Boateng, A.A. Pyrolysis and Bio-Oil. Agriculture and
Natural Resources. University of Arkansas Division of Agriculture
FSA #1052. Accessed on May 2016 at <
http://www.uaex.edu/publications/pdf/fsa-1052.pdf>. cited by
applicant .
Hagner, Marleena. 2013. Potential of the slow pyrolysis products
birch tar oil, wood vinegar and biochar in sustainable plant
protection-pesticide effects, soil improvement and environmental
risks. Academic Dissertation in Environmental Ecology. Presented
Sep. 20, 2013 at the University of Helsinki. cited by applicant
.
Czernik, S.; Bridgwater, A.V. 2004. Overview of Applications of
Biomass Fast Pyrolysis Oil. Energy and Fuels. vol. 18: pp. 590-598.
cited by applicant .
Diebold, J.P. 1997. Overview of Fast Pyrolysis of Biomass for the
Production of Liquid Fuels. Developments in Thermochemical Biomass
Conversion. Chapter: pp. 5-26. cited by applicant .
Xiu, Shuangning; Shahbazi, Abolghasem. 2012. Bio-oil Production and
Upgrading Research: A Review. Renewable and Sustainable Energy
Reviews. vol. 16: pp. 4406-4414. cited by applicant .
Bridgwater, A.V.; Peacocke, G.V.C. Engineering Developments in Fast
Pyrolysis for Bio-oils. Biomass Pyrolysis Oil Properties and
Combustion Meeting in Golden, CO. Accessed on Jun. 21, 2016 at <
http://digital.library.unt.edu/ark:/67531/metadc665006/m1/121/>.
cited by applicant .
Bridgwater, A.V. 1999. Principles and practice of biomass fast
pyrolysis processes for liquids. Journal of Analytical and Applied
Pyrolysis. vol. 51: pp. 3-22. cited by applicant.
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Primary Examiner: Robinson; Renee
Assistant Examiner: Gitman; Gabriel E
Attorney, Agent or Firm: Burris Law, PLLC
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent
Application Ser. No. 62/153,130, titled "Gasification and Drying
Apparatus," filed Apr. 27, 2015, the contents of which are
incorporated herein by reference in their entirety.
Claims
What is claimed is:
1. A system for treatment of a moisture-containing or water-laden
material, the system comprising: a rapid compression unit (RCU)
apparatus having a compression screw, a barrel, and one or more
flow disrupters mounted on an interior surface of the barrel
positioned in a passageway formed between the screw and the
interior surface of the barrel, the screw operable for rotating at
a speed to produce friction and compression to generate a desired
raised temperature within the barrel; and a feeding mechanism for
feeding a moisture-containing material to the RCU apparatus;
wherein the RCU is adapted to receive, heat, and mix the moisture
containing material along a longitudinal axis defined by the barrel
and the screw and output a heat treated bio-product and exhaust
gas.
2. The system according to claim 1, further comprising a reflux
condenser for receiving the bio-product from the RCU apparatus, and
a second condenser for receiving and condensing volatile gasses
resulting from the treatment in the RCU apparatus, wherein a
resultant condensate from the reflux condenser is either combined
with a condensate from the second condenser or directly fed to an
aftercooler for additional cooling to form a treated bio-product
which is then fed to an exit mechanism.
3. The system according to claim 2, wherein the second condenser is
a shell and tube condenser and is adapted to (i) receive syngas
from the RCU apparatus, and (ii) condense the syngas to produce
bio-oil.
4. The system according to claim 2, further comprising a manifold
apparatus operatively connected to the RCU to direct gasses to the
second condenser.
5. The system according to claim 1, wherein the one or more flow
disrupters are operable to cause the moisture or water-laden
material to fold over onto itself, thereby providing more uniform
heat treatment.
6. The system according to claim 1, wherein the one or more flow
disrupters is a metal component that is individually selected to
define a geometric shape selected from the group consisting of a
square, rectangular, triangular, trapezoidal shape, and
combinations thereof.
7. The system according to claim 1, wherein the one or more flow
disrupters comprises a plurality of flow disrupters and the flow
disrupters are spaced apart either radially about the inner
diameter of the barrel or continuously spaced throughout the
barrel.
8. The system according to claim 1, further comprising a control
system for adjusting the barrel relative to the screw.
9. The system according to claim 1, further comprising a nozzle
connected to the RCU apparatus in conjunction with one or more
adjustable air/oxygen inlet ports to perform any one of direct
heating, drying, steam production and combinations thereof.
10. The system according to claim 8, further comprising at least
one or more of a supplemental gas inlet port, an ignitor, and
combination thereof coupled to the nozzle.
11. An apparatus for treatment of a moisture-containing or
water-laden material, the apparatus comprising: an elongated barrel
of fixed volume extending along a longitudinal axis, the barrel
having a feeding section for receiving moisture-containing material
from a feeder; a compression screw positioned within the barrel
extending along the length of the barrel along the longitudinal
axis; and at least one flow disrupter located on an inner surface
of the barrel and projecting into a passageway formed by the screw
and the barrel; wherein the barrel is adapted to receive, heat, and
mix the moisture-containing material along the longitudinal axis
defined by the barrel and the screw and output a heat treated
bio-product and exhaust gas.
12. The apparatus according to claim 11, wherein the at least one
flow disrupter is a metal component that defines a geometric shape
selected from the group consisting of a square, rectangular,
triangular, trapezoidal, polygonal shape, and combinations
thereof.
13. A method of treating a moisture-containing or water-laden
material to produce a bio-product, the method comprising the steps
of: providing a moisture-containing or water-laden material;
providing a rapid compression unit (RCU) system including: an RCU
apparatus having a compression screw, a barrel, and one or more
flow disrupters mounted on an interior surface of the barrel
positioned in a passageway formed between the screw and the
interior surface of the barrel, the screw operable to rotate at a
speed to produce friction and compression to generate a desired
elevated temperature within the barrel; and a feeding mechanism
adapted to receive the material and feed the material to the RCU
apparatus, feeding the moisture-containing or water-laden material
to the RCU system using the feeding mechanism; mixing and heating
the moisture-containing or water laden material in the RCU
apparatus such that the moisture-containing or water laden material
separates into at least steam and a bio-product material; and
removing the bio-product material from the RCU apparatus.
14. The method according to claim 13, wherein the one or more flow
disrupters cause the water-laden material to fold over onto itself,
thereby, providing more uniform heat treatment.
15. The method according claim 13, wherein the RCU apparatus
subjects the moisture-containing or water-laden material to a
temperature at or above its autoignition temperature, thereby
subjecting the water-laden material to the steps of steam pyrolysis
then rapid compression, steam explosion, and
recapture/carbonization.
16. The method according to claim 13, wherein the RCU apparatus
subjects the moisture-containing or water-laden material to a
temperature that is below its autoignition temperature, thereby
subjecting the water-laden material to the steps of steam drying,
steam explosion, and cooling.
17. The method according to claim 13, wherein the one or more flow
disrupters includes a plurality of flow disrupters and the flow
disrupters are spaced apart either radially about the inner
diameter of the barrel or continuously spaced throughout the
barrel.
18. The method according to claim 13, wherein the method further
comprises using a nozzle connected to the RCU apparatus in
conjunction with one or more adjustable air/oxygen inlet ports to
perform any one of direct heating, drying, steam production and
combinations thereof.
19. The method according to claim 13, further comprising the steps
of providing a reflux condenser and receiving the bio-product from
the RCU apparatus, and a second condenser for receiving and
condensing any volatile gasses to form a condensate resulting from
the treatment in the RCU apparatus, wherein a resultant condensate
from the reflux condenser is either combined with the condensate
from the second condenser or directly fed to an aftercooler for
additional cooling to form a treated bio-product which is then fed
to an exit mechanism.
20. The method according to claim 13, wherein the second condenser
is a shell and tube condenser and receives syngas from the RCU
apparatus which is condensed to produce bio-oil.
Description
FIELD
The present disclosure relates generally to an apparatus and method
used to heat treatment such as gasification and drying of
materials. More specifically, this disclosure relates to system,
equipment, and methods that improve the performance and efficiency
of production processes used to heat treat cellulosic materials,
biomass materials, coal, or other materials for the production of
bio-products.
BACKGROUND
The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
A conventional wood gasification apparatus uses only the friction
created by a fixed screw and barrel. The screw design is typically
one of a continuous decreasing design which increases the pressure
on the cellulosic material and maximizes the frictional heating
until the material reaches a temperature above its auto ignition
temperature. Once the vaporization temperature is reached, the
cellulosic material is converted into a combination of combustible
fuel gases that typically contains a mixture of methane, hydrogen
and carbon monoxide. Any particulate material that is present is
frictionally heated and propelled along the auger until it reaches
a plasticizing or softening temperature and forms an in-situ seal
between the auger and the housing. This in-situ seal prevents gas
from flowing back along the auger to the housing inlet.
However, in practice, a conventional wood gasification apparatus is
also prone to plugging as the particulate material is carburized.
This plugging can be catastrophic, shutting down the process by
overloading the electrical current and/or shearing coupling drives
and/or bolts. Additionally, the plasticizing seal is minimal to
non-existent when processing non-woody biomass due to lower lignin
content. Once a plug forms, the unit must be allowed to off-gas,
cool to below the auto ignition temperature and then be
disassembled for cleaning. The carbonized mass must be scraped from
the threads and inside of the housing, a process that takes hours,
which results in substantial lost production time.
A rotary biomass dryer provides a low cost alternative to
conventional biomass drying. The rotary biomass dryer requires no
external energy, only a motor to rotate the compression auger
effectively heating the biomass by compression and friction to
generate in-situ steam.
The rotary biomass dryer, which often has an adjustable nozzle, is
also equipped with a compression screw. Similar to the wood
gasification apparatus, the rotary biomass dryer is prone to
plugging, which results in hours, if not days, to clean and restart
the process. On rotary biomass dryers powered by 100-250
horsepower, the plugging may occur without notice and require a
large hydraulic jack to extract the screw. In addition, the biomass
dryer is deployed with an adjustable nozzle that is cumbersome and
prone to high wear. During processing, only the biomass in direct
contact with the compression screw or elongated tube is dried
during the process.
SUMMARY
The present disclosure generally provides an apparatus, a system,
and a method for heat treating a moisture-containing or water-laden
material to produce a bio-product. The system includes a rapid
compression unit (RCU) apparatus having a compression screw, a
barrel, and one or more flow disrupters. The flow disrupters are
mounted on an interior surface of the barrel positioned in a
passageway formed between the screw and the interior surface of the
barrel, and in one form, such that the screw and the one or more
flow disrupters do not touch. The screw is operable for rotating at
a speed to produce friction and compression to generate a desired
raised temperature within the barrel.
The system further includes a feeding mechanism for feeding a
moisture-containing material to the RCU apparatus. The RCU
apparatus is adapted to receive, heat, and mix the
moisture-containing material along a longitudinal axis defined by
the barrel and the screw and output a heat treated bio-product and
exhaust gas. The system can further include a reflux condenser for
receiving the bio-product from the RCU apparatus and a second
condenser for receiving and condensing any volatile gasses
resulting from the treatment in the RCU apparatus. The resultant
condensate from reflux condenser is either combined with the
condensate from the second condenser or directly fed to an
aftercooler for additional cooling to form a treated bio-product
which is then fed to an exit mechanism. In an example, the second
condenser is a shell and tube condenser and is adapted to (i)
receive syngas from the RCU apparatus, and (ii) condense the syngas
to produce bio-oil.
In yet another example, the one or more flow disrupters are
operable to cause the moisture or water-laden material to fold over
onto itself, thereby, allowing for more uniform heat treatment. The
one or more flow disrupters each represent a metal component that
is individually selected to define a geometric shape selected from
the group consisting of a square, rectangular, triangular,
trapezoidal shape, and combinations thereof. In still another
example, the one or more flow disrupters define a plurality of flow
disrupters and the flow disrupters are spaced apart either radially
about the inner diameter of the barrel or continuously spaced
throughout the barrel.
The system can further include a control system for adjusting the
barrel relative to the screw using precision controls and simple
hydraulic currents. A nozzle can be provided that is connected to
the RCU apparatus in conjunction with one or more adjustable
air/oxygen inlet ports to perform any one of direct heating,
drying, steam production and combinations thereof. The nozzle can
further include at least one or more of a supplemental gas inlet
ports, an ignitor, and combination thereof coupled to the
nozzle.
According to another aspect of the present disclosure, a material
is dried according to the method and/or using the apparatus or
system described above and further disclosed herein. The material
being dried may be, without limitation, a cellulosic material, a
biomass material, or coal.
Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DRAWINGS
In order that the disclosure may be well understood, there will now
be described various forms thereof, given by way of example,
reference being made to the accompanying drawings in which:
FIG. 1 is a schematic representation of a rotary biomass rapid
compression unit (RCU) system according to the teachings of the
present disclosure;
FIG. 2 is schematic representation of the rotary biomass RCU of
FIG. 1 operated below an autoignition temperature;
FIG. 3 is schematic representation of the rotary biomass RCU of
FIG. 1 operated above an autoignition temperature;
FIG. 4 is a schematic representation of a rotary biomass RCU system
further including a second condenser coupled to the RCU and an
aftercooler and constructed in accordance with the teachings of the
present disclosure;
FIG. 5 is a cross-sectional view of a screw and barrel assembly for
the rotary biomass RCU of FIGS. 1-4;
FIG. 6 is a schematic representation of a nozzle to enhance
efficiency for a gasification apparatus in accordance with another
form of the present disclosure; and
FIGS. 7A and 7B illustrate a shell and tube condenser according to
the teachings of the present disclosure.
The drawings described herein are for illustration purposes only
and are not intended to limit the scope of the present disclosure
in any way.
DETAILED DESCRIPTION
The following description is merely exemplary in nature and is not
intended to limit the present disclosure, application, or uses. It
should be understood that throughout the drawings, corresponding
reference numerals indicate like or corresponding parts and
features.
The present disclosure addresses the treatment of
moisture-containing or water laden materials by providing an
apparatus and method that adapts a rapid compression unit (RCU) for
drying or gasification or bio-char/bio-coal formation to enhance
efficiency and to reduce the occurrence of plugging during
operation. Plugging may be defined as the formation of a dense mass
that obstructs a passageway in a barrel of a dryer or gasification
system. The occurrence of plugging causes an undesirable increase
of pressure within the barrel. One skilled in the art will
understand that the apparatus and method of the present disclosure
is described throughout the present disclosure in conjunction with
a rotary biomass RCU that can be used for treating with heat
produced through friction and compression to form biomass materials
in order to more fully illustrate the apparatus and method. The
incorporation and use of such an apparatus in other types of
systems to dry or form other materials is contemplated to be within
the scope of the present disclosure. The material being formed may
be, without limitation, a cellulosic material, a biomass material
such as bio-oil, bio-char and bio-coal and other bi-product
thereof.
Biomass materials are generally a mixture of three basic cellulosic
materials, namely, cellulose, hemicellulose and lignin along with
interstitial bound and unbound water. A rotary biomass dryer
functions as a compression dryer or steam dryer as it uses the heat
of compression as the Second Law of Thermodynamics is deployed to
produce steam by compression and friction thereby effectively
drying the wet biomass material. In an example, the treatment of
biomass materials can fall into three broad categories or ranges,
namely, mere drying or dehydration/rectification which can be
referred to as non-destructive drying, an intermediate treatment
step which includes at least partial destruction, which can be
referred to as torrification and carbonization, and destructive
drying which encompasses the complete carbonization of cellulosic
material. Mere drying, which can mean operating temperature of up
to about 250.degree. C. means the removal of unbound water which
can create steam. Mere dehydration occurs typically between
200.degree. C. and 235.degree. C. Rectification can occur between
235.degree. C. and 250.degree. C. which includes the removal of
bound water as well. The rotary screw typically can operate at a
suitable RPM to achieve this desired temperature. In an example,
the RPM for an example six-inch or twelve-inch diameter compression
screw to achieve these temperatures can be between 600-800 RPM.
For an intermediate treatment range, the RCU typically functions in
the semi-destructive range, between a temperature of about
250.degree. C. and 400.degree. C. Within this temperature range,
both unbound waters and bound waters are released from the biomass
materials as well as additional syngas. This also forms biochar
characterized by having some carbonization and porosity. Typically,
a torrification range is between 250.degree. C. and 270.degree. C.
and above that is considered carbonization (270.degree.
C.-400.degree. C.). In an example the rotary screw typically can
operate at a suitable RPM to achieve this desired temperature. In
an example, the RPM for an example six-inch or twelve-inch diameter
compression screw to achieve these temperatures can be between
800-1200 RPM.
Treatment above 400.degree. C. is considered destructive because it
creates biochar that can be fully carbonized, thus removing all
water from the material as well as reactive products from the
destruction and carbonization of the starting cellulosic material.
This can also be referred to as gasification. In an example the
rotary screw typically can operate at a suitable RPM to achieve
this desired gasification temperature. In an example, the RPM for
an example six-inch or twelve-inch diameter compression screw to
achieve these temperatures can be above 1200 RPM.
Referring to FIG. 1 a rotary biomass rapid compression system (1)
is shown and generally includes a feeding mechanism (5), a rotary
biomass rapid compression unit (RCU) apparatus (10), a reflux
condenser (15), an aftercooler stage (20), and an exit mechanism
(25). The system can further include an additional condenser shown
in FIG. 3 that runs parallel with the reflux condenser depending on
the intended purpose of system (1). Along the entire length of the
system (1), the various portions of the system (1) may also be
described to include various zones, namely, auto acid hydrolysis
(30), rapid compression (35), steam explosion (40), recapture
carbonization (45), and cooling condensation (50). Some of these
zones may overlap with one another as shown in FIG. 1 with respect
to the rapid compression zone (35) and the steam explosion zone
(40). The biomass material may be subjected to any of these zones
either individually or in any combination depending on the desired
output. Further details associated with a rotary mass dryer system
and a wood gasification system are described in U.S. Pat. Nos.
8,667,706 and 7,144,558, respectively, the entire contents of which
are hereby incorporated by reference.
A rotary biomass RCU apparatus 10 may perform better with a uniform
feed rate in order to achieve a relatively high efficiency. In
other words, it is desirable that the apparatus maintains a uniform
flow rate provided by feeding mechanism 5. Thus the rotary biomass
RCU system (1) may include one or more feed improvements, namely, a
crammer feeder, an in-feed mixer, a preheater, and/or a dual belt
feeder to enhance the uniformity of the flow rate. The rotary
biomass RCU system may also incorporate the use of a pretreatment,
such as without limitation in-situ acid treatment, e.g., auto acid
hydrolysis or inorganic sequestering. Further details associated
with feed improvements and pretreatment can be found in co-pending
U.S. patent application Ser. No. 15/066,894, filed Mar. 10, 2016,
which claims priority to U.S. Provisional Patent Application No.
62/130,820 filed Mar. 10, 2015, the entire content of which is
hereby incorporated by reference. In an example, a crammer feeder
is used as described in the Ser. No. 15/066,894 application, which
provides a uniform feed rate to reduce dust created by windage,
which may result from the compression unit.
Referring now to FIGS. 2 and 3, pressure (60) and temperature (70)
that occurs in a biomass RCU system (1) increase during its
operation as the biomass material moves from the feeding mechanism
(5) through the RCU (10). In an example, the temperature (70) and
pressure (60) increases through the pretreatment or precompression
(e.g., auto acid hydrolysis) stage (30) and the rapid compression
or steam drying or pyrolysis stage (35). The pressure reaches a
peak during the rapid compression or steam drying/pyrolysis stage
(35) and then rapidly decreases as the biomass moves through the
steam explosion stage (40) or from the biomass dryer (10) into the
reflux condenser (15). In the example of FIG. 3 (discussed below),
syngas can be captured and condensed into bio-oil using a second
condenser. A manifold apparatus can be useful in capturing the gas
and feeding it into the second condenser. In the example of FIG. 3,
a shell and tube condenser is used. When the temperature (70) does
not reach the autoignition temperature limit, a
recapture/carbonization stage does not occur, but rather the
biomass material moves from steam drying (35a) directly into the
cooling stage (50) as shown in FIG. 2. However, when the
temperature (70) does reach the autoignition temperature limit, a
recapture/carbonization stage (45) occurs following the steam
pyrolysis (35b) stage and the initiation of the cooling stage (50)
is delayed as shown in FIG. 3.
Referring to FIG. 4, an exemplary rapid compression system (1) is
shown with a dual parallel condenser construction. This form is
especially useful in forming bio-char, bio-oil, and bio-coal,
depending on the desired result, particularly for the intermediate
treatment scenario described hereinabove. In this example, a rotary
biomass RCU system (1) is shown and generally includes a feeding
mechanism (5), a rotary biomass RCU (10), a reflux condenser (15),
a second condenser (300), a manifold apparatus (315), an
aftercooler stage (20), and an exit mechanism (25). The second
condenser (300) can run parallel with the reflux condenser (15)
depending on the intended purpose of system (1).
In an example, under certain operation conditions, such as during
an intermediate treatment, syngas is produced through the RCU unit
(10) which can be captured in a gas manifold apparatus (315).
Partial condensation can occur of the gasses in manifold apparatus
(315) which is then fed into the second condenser (300). Condenser
(300) can be a shell and tube condenser as described in more detail
below related to FIGS. 7A and 7B. Condenser (300) can produce a
liquid condensate (325) which can be referred to as bio-oil. The
resulting condensate (325) produced in condenser (300) can be used
in a variety of ways. Bio-oil can be separated on its own from
remaining gasses and be used for a variety of purposes.
Alternatively, the bio-oil or condensate (325) product can be
recombined with the resultant bio-product (i.e., bio-char or
bio-coal) produced in the reflux condenser (15). The bio-oil (325)
from condenser 300 can be sprayed over or fed to the bio-product
leaving condenser (15) and it can be recombined at any point
throughout aftercooler (20). Combining the bio-oil from the second
condenser (315) with the bio-product from the reflux condenser (15)
can produce a bio-coal.
Bio-char is defined as a bio-product material that has some
carbonization along with a given porosity. The bio-oil that can be
formed through condensation in both the reflux condenser and the
second condenser can be condensed back into the bio-char and thus
forms a bio-coal. A bio-coal has a significantly reduced porosity
but has a much higher BTU content and thus can provide a desirable
fuel bio-product.
Referring now to FIG. 5, an exemplary cross-sectional view of a
screw (130) and barrel (100) assembly as part of the RCU (10) is
shown. Barrel (100) can be an elongated housing for supporting and
allowing screw (130), which in one form is tapered as shown in FIG.
6, to create compression along and through a longitudinal axis
defined by barrel (100). In order to reduce the occurrence of
plugging in the barrel (100) of the RCU apparatus, one or more flow
disrupters (110) can be installed in the form of a shaped metal
component located on the inside of the barrel (100). The flow
disrupters (110) project into the passageway (120) formed between
the screw (130) and barrel (100) through which the biomass material
flows. In one form, the flow disrupters (110) are designed so that
they do not make contact with the screw (130).
The shape of the flow disrupters (110) may individually be selected
as defining any geometric shape, including but not limited to
square, rectangular, triangular, or trapezoidal shape, among
others. Since the metal component is three-dimensional (3-D) by
nature, the overall shape of each flow disrupter (110) may include
a singular shape or a mixture of shapes. For example, a metal
component with all sides being square may be represented as a
cube.
The flow disrupters (110) serve at least two purposes: 1) to assist
in converting the rotary motion of the biomass as it is compressed
to linear direction; and 2) mixing the biomass such that the
biomass flows over onto itself, thereby, allowing for the
occurrence of more uniform drying. A single flow disrupter (110)
may be utilized or when desirable a plurality of flow disrupters
(110) can be used. In an example, the plurality of flow disrupters
(110) can be spaced either radially and optionally, uniformly,
about the inner diameter of the barrel 100 and/or continuously
spaced throughout the barrel (100). The use of the flow disrupters
is found to improve overall throughput and enhance quality of the
biomass material through the rotary biomass dryer system.
According to another aspect of the present disclosure, the
adjustable nozzle on a conventional rotary biomass dryer, which is
cumbersome and prone to wear, as well as difficult to accurately
adjust can be replaced by providing a means to actually adjust the
barrel relative to the screw. Adjusting the barrel in relation to
the screw using precision controls and simple hydraulic currents
has been found to accomplish the same function as the adjustable
nozzle used in conventional dryers.
Referring now to FIG. 6, an exemplary dryer or gasification unit
(200) is shown. The efficiency of unit (200) can be enhanced when
it includes a nozzle (210) designed such that it allows for direct
heating, drying, or steam production in conjunction with one or
more adjustable air/oxygen inlet ports (220). Optionally, the
nozzle (210) may include one or more supplemental gas inlet ports
(230) or ignitors (240). Optionally, the addition of a particle
filter and/or a condenser (such as a shell and tube), or the like,
can be used to allow unit (200) to produce bio-oils.
Referring to FIGS. 7A and 7B, an example second condenser (300)
from FIG. 3 is provided. Condenser (300) can be a shell and tube
condenser. Condenser (300) can include an outer shell (302) formed
around tubes that extend from inlet (301) that vents through vent
(303). Gasses, such as syngas that can be released through the
condenser can include but are not limited to carbon monoxide,
carbon dioxide, and hydrogen. Coolant can be provided through
coolant inlet (306) and exiting through coolant outlet (307). The
particle trap (305) can include a cap (308). A drain (304) is
provided to collect liquid condensate. The liquid condensate (325)
from FIG. 4, can be bio-oil and collected separately or combined
with the bio-product from the reflux condenser (15).
In an example, reflux condenser (15) can receive porous biochar
from the compression unit such that a formed char passes through an
exothermal condition that devolatilizes the char allowing for a
cooling down phase to occur and to receive the gasses through a
cooling auger. The reflux condenser can also receive vapors from
the compression unit and condense it to a condensate. Gasses that
flow into the reflux condenser can be referred to as bio-oil and
can be condensed into the particles of the bio-char thus forming a
bio-coal. In a further example, the condensate from the second
condenser can be sprayed on the bio-product or processed into
bio-products of the reflux condenser.
The foregoing description of various forms of the invention has
been presented for purposes of illustration and description. It is
not intended to be exhaustive or to limit the invention to the
precise forms disclosed. Numerous modifications or variations are
possible in light of the above teachings. The forms discussed were
chosen and described to provide the best illustration of the
principles of the invention and its practical application to
thereby enable one of ordinary skill in the art to utilize the
invention in various forms and with various modifications as are
suited to the particular use contemplated. All such modifications
and variations are within the scope of the invention as determined
by the appended claims when interpreted in accordance with the
breadth to which they are fairly, legally, and equitably
entitled.
* * * * *
References